Melting and Holding October 08

252 FTJ October 2008
Primary materials have become limited on the

global market, causing an increase in prices
that have reached a new level in 2008. But there
are ready-to-use alternatives for foundries that
can help economise in a difficult procurement
situation.
Because of the hike in raw material prices for
coke as well as for steel scrap that has been on-
going since 2002, availability of these materials
in the German market suffered badly, and foundry
coke was even apportioned for
some time. After the situation
had eased somewhat in 2007,
a new hike of prices ensued at
the beginning of 2008, mainly
due to the growing dependence
on China and other rapidly
developing countries for raw
material deliveries, such as
foundry coke.
From that background, it
is essential for foundries in
Germany and across the EU to
explore new ways to cope with
the tight price situation on the
world market and shortages of
raw materials, plus changes in
their quality in order to assure
cost-effectiveness when melting
in the cupola.
Meeting material
requirements
Implementation of a consequent
points-of-accrual-management
(recyclers/foundries) is one
way to ensure the increasing
requirements for charge
material are met and to provide
such materials with consistent
quality to foundries.
The aim of this publicly
funded research project
was to provide new ways of
substitution for small and
medium-sized foundries.
Substitutes that were
investigated included briquettes
made from GJL, GJS and mixed
GS / GJS borings and from
grinding swarf, as well as
alternative sorts of steel scrap
such as micro-alloyed, shredded
Alternative charge materials for the cupola
It doesnt always have to be primary raw materials for cupola
melting, say Gotthard Wolf, Herbert Lblich and Timo Wysocki from
the Institut fr Gieereitechnik IfG gGmbH, Dsseldorf.
Fig 1. C-bricks with mixed borings may
be magnetised and then charged using
a magnet crane
Fig 2. HCS testing of self-reducing c-bricks (left) and apparatus (right). Specimen (hatched) is placed
between two refractory pistons within a protective tube, heated up to the desired temperature and then
loaded until breakage (left). (Photo courtesy of DIFK, Bonn)
FTJ October 2008 253
Melting and Holding
or electroplated steel scrap
that are drawn into the focus of
foundries.
In addition, fuel substitutes
available on the market
such as blast furnace coke,
Chinese foundry coke or lime-
malm bonded c-bricks were
investigated and synthetic
charge materials such as self-
reducing c-bricks or c-bricks
with admixed borings that make
these briquettes magnetisable
were developed especially for
this project.
Pre-testing of the alternative
charge materials was
emphasised during the entire
project. Testing methods
included cold compressive
strength (CCS) and hot
compressive strength (HCS)
at temperatures of 800C,
reduction under load (RuL)
and drop shatter testing, fuel
analysis, abrasion strength,
analysis of the chemical
composition of metallic charge
materials and trace elements
analysis.
Conditioning and briquetting
technology for borings
briquettes and c-bricks was
investigated and optimised,
including experiments using an
industrial briquetting press with
150 tonnes maximum load.
Cupola melting trials
Melting trials were carried out
in two NRW foundries equipped
with cold-blast cupolas with
respective melt rates of five
and eight tonnes per hour.
During these trials, emphasis
was placed on the complete
coverage of all input and output
parameters. These included:
iron temperature, blast
pressure, iron, slag and gas
composition, dust, inoculation
and mechanical properties of
the iron. The results showed
most of the alternative charge
materials can be used safely
up to a certain amount.
Borings from the machining
of castings can be considered
as an ideal substitute for the
metallic charge if their chemical
composition is consistent and
they are briquetted.
Within the series of trials,
briquettes made from borings
with CCS of more than 20MPa
were used to replace up to 60%
of iron without affecting blast
pressure. From that, it was
concluded that the briquettes
remained sturdy until their
meltdown. It was also possible
to replace all the steel scrap
and pig iron from the metallic
charge with borings briquettes.
Furthermore, c-bricks with
admixed GJS borings were
developed as a substitute for
both coke and the metallic
charge, and self-reducing
c-bricks made of coke breeze
and iron oxide were developed
as a substitute for steel scrap
and pig iron. Aluminium
phosphate was used as a
binder for that, as the special
advantages of this material
compared to cement and other
binders became apparent in
preliminary experiments.
It was found safe to use these
c-bricks in amounts up to about
10% of the metallic charge,
providing compression strength
exceeded 1.8MPa. For the self-
reducing c-brick, a degree of
reduction of 99% of the included
Fe
2
O
3
could be proven through
slag analysis. These bricks can
be used for replacing steel
scrap without problems.
C-bricks with admixed
borings are also suitable
and can be charged with the
usual magnet crane (fig. 1),
offering an advantage for small
foundries in that no further
investment cost for a second
coke bunker is required when
substituting foundry coke
with alternative fuels. They can be produced with
moderate investment and manpower or purchased
(which is likely to be the more economic solution
for medium and small-sized foundries) from a
commodity trader.
None of the alternative charge materials caused
significant metallurgical disadvantages concerning
trace elements, nucleation and chill depth when
tested - even in high amounts during the trials.
No increase in scrap was found in either foundry
during the period of the trials.
Monitoring dust and odour
During the trials, dust and odour emissions were
observed at the de-dusting plants. Samples for
analysis were taken directly from the undiluted
raw gas from the stack and analysed with methods
according to olfactometric standard EN 13725
(1)
.
Dust measurements in front of and behind the filter
did not show significant changes in dust emission
and composition during any of the trials, except
for the trials with borings and grinding swarf
briquettes.
For these materials, a relation between oil and
cutting fluid residue and the odour emission was
developed and it was shown that odour emission
increased with an increase in total oil and cutting
fluid residue charged (fig. 5). Nevertheless, it
should be considered that the effective odour
effluents in the neighbourhoods of the foundries
are subjected to a variety of influences, such as
weather, direction of the wind, moisture, height
of the stack, distance between the foundry and its
neighbours, topography of the surroundings etc.
Producers of briquettes made from borings are
therefore required to ensure low enough oil and
cutting residue, one possible solution being the
combination of borings from dry and from wet
machining to a mixture with low residue.
Cost-effectiveness of the alternative charge
materials tested within this project depends on
the market situation and on the availability of
the alternative materials to the foundries. The
0
20
40
60
80
4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 5.0
Apparent Density [g/cm!]
C
C
S

/

H
C
S

[
M
p
a
]
B504 (45 bar) B503 (70 bar)
B502 (90 bar)
HCS
B502 (90 bar)
Fig 3. Comparison between CCS at various compaction pressures and HCS of borings briquettes
Moulding and Coremaking
are likely to increase further
in the future, foundries will
be able to flexibly adapt their
charge composition with the
results of this project.
Reference
1. Helber J, Odour emission
reduction in foundries
- a report on the state
of the art, 66th World
Foundry Congress, Casting
technology - 5000 years
and beyond, Vol 1, Istanbul,
Turkey, Sep 6-9, 2004.
Acknowledgements
This research project was
funded by the NRW Ministry
of Innovation, Research and
Technology (funding no. 005-
0410-0005, in responsibility of
Forschungszentrum Jlich, file
number PTJ-Az. 0410MW14).
The authors also wish to
express their gratitude to
the foundries involved in
this project for making the
investigations possible during
regular operation.
About the authors
The authors are Dr-Ing Herbert
Lblich (cupola melting,
cast iron production); B E
Timo Wysocki (briquetting
technology, binder systems);
and Dr-Ing Gotthard Wolf, IfG
Institute of Foundry Technology,
Dsseldorf (Germany).
Gieereiingenieur (BE) Metallurgie
und Werkstofftechnik, Institut
fr Gieereitechnik IfG GmbH,
Dsseldorf, Germany;
Tel: +49 (0) 211 6871 327;
fax: +49 (0) 211 6871 255;
email: Wysocki@ifg-net.de
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scatter range of standard charge composition B
oil / cutting fluid residue
1,45 %
3,41 %
2,64 %
1 OU = 1 EROM = 123 "g n-Butanol / 1 m3 neutral gas = 0,04
"mol/mol
situation is likely to improve with rising demand
for these materials, which should result in
increased investment of re-cyclers and foundries
into advanced briquetting technologies and to
emphasising the closing of idle material cycles
in foundries. The latter is
further accelerated through
government subsidies for
material effectiveness.
As prices for charge materials
Melting and Holding
Fig 4. Briquettes made from borings can be an ideal substitute for the metallic charge
Fig 5. Odour emissions increased with oil residue
NRW Ministry of Innovation, Science, Research and Technology
The Ministry of Innovation, Science, Research and Technology of the state of North Rhine-Westphalia (NRW) in its
present form was established in June 2005. This is the first time that a German Ministry has focussed on a states
potential for innovation as a top priority.
The Ministry is responsible for all NRW-based universities and polytechnics, university clinics, colleges of art or
music, for non-university research institutions and for the promotion of technologies in the state.
The remit of the Ministry of Innovation, Science, Research and Technology reflects the entire innovation process
ranging from higher education training to university and non-university research on developments and inventions and
to industrys activities aimed at making applications ready for the market and successfully marketing fundamental
innovations.
The Ministrys objectives include: achieving excellence in research and higher education teaching in NRW, boosting
exchanges between the research and business communities, and considerably improving NRWs technological capacity.
NRW boasts Europes most closely set research and higher education infrastructure.
The NRW government is firmly resolved to bring the state to the forefront of scientific, technological and economic
progress and to turn NRW into Germanys number one innovation state by the year 2015.
www.innovation.nrw.de
Melting and Holding
Faced with increasing energy prices, in 2007
Alumasc Precision - the Burton Latimer,
England, based aluminium diecaster, made a
comprehensive review of its energy use and costs
associated with melting and holding aluminium
for its high-pressure diecasting facilities. A
detailed appraisal showed that there would be
significant cost savings and reduction of carbon
emissions by installing a new high-efficiency bulk
melting and holding furnace to replace some of
the existing older gas-fired crucible furnaces.
The new bulk melting furnace was supplied and
installed by the German company ZPF therm
GmbH of Siegelsbach.
Space was very limited in the chosen location
in Alumascs high-pressure foundry, but ZPFs
very compact, highly efficient design meets
Alumascs energy reduction targets, and
complies with the latest mandatory emissions
limits without the need for filtering systems.
Norbert Feth, marketing manager of ZPF
therm GmbH explains: The reason for such
low emission lies in the unique design of ZPF
therms furnaces. The core of the system is
the combustion chamber, which is made of
refractory concrete and weighs several tonnes.
The thick encasement functions as a protective
barrier between the thermal insulation layers
and external steel casing on one hand, and the
aggressive liquid aluminium on the other.
The heavy refractory lining also serves as
a heat accumulator that helps to maintain a
steady state interior temperature of the furnace.
A sophisticated system of insulation keeps the
thermal energy in the interior of the furnace and
contributes significantly to energy saving.
Reduction of emissions
An unconventional exhaust gas flow from the
melting chamber plays a very significant role
in the reduction of the furnaces emissions
to air. Rather than being expelled directly to
atmosphere from the melting shaft through
a chimney as is typical in other furnaces, flue
gases are first held in the interior of the self-
contained system. In the process, residues from
the charged material - particularly those from
returns - are subsequently virtually combusted.
This means that complex filtration systems are
unnecessary.
The measured emissions values fall far
below the statutory limits. ZPF claims that the
proportion of particulate matter in waste gases
is less than three milligrams per cubic metre,
for nitrogen oxide, the value is about eleven
milligrams and only 0.4 milligrams for hydrogen fluoride.
Herr Feth speculates: Even if the limits become yet stricter in five
years time, we will still be able to meet without external filtering.
The longer dwell time of the hot gases in the furnace chamber
also contributes greatly to the high energy-efficiency of the furnace.
ZPF therm say there is an average of 20 to 30% more performance
capacity through this method of optimal heat utilisation rather than
with open exhaust gas systems.
The furnace installed at Alumasc is rated to melt one tonne per
hour of aluminium alloy and has a holding bath capacity of two and a
quarter tonnes. The unique gas firing system employs two modulating
nozzle-mixing gas burners with automatic air/gas ratio control. Both
burners are used when the furnace is in the melting mode to give
rapid melting which reduces metal loss. Only one of the burners is
used when maintaining to give better turn-down and consequently
more accurate temperature control.
Integrated charging
An integrated charging machine automatically loads aluminium ingots
and foundry returns that are pre-loaded in wheeled charge cars.
The furnace is mounted on load cells giving the operators accurate
information of the weight of metal in the furnace. The weighing
system also controls the charging machine to automatically prevent
over-filling the furnace.
Weight monitoring allows the PLC system to accurately calculate the
melting time for each charge according to the weight and regulate the
time on high-fire, which saves energy and prevents over heating and
associated oxidation losses.
After a years continuous operation, the furnace has met Alumascs
expectations regarding energy cost saving and reduced emissions. An
inspection during the recent annual shut-down showed only minimal
lining wear; the furnace needed only general cleaning of dross and
metal residues.
Ramsell-Naber is the sales and service representative of ZPF for the UK and
Ireland. ZPF specialises in gas- and oil-red furnaces mainly for the aluminium
casting industry. The company has a unique range of furnaces for bulk melting
and holding, with melting rates up to ve tonnes per hour and holding capacities
up to 20 tonnes.
Ramsell-Naber Ltd; Tel: +44 (0) 1922 455521; fax: +44 (0) 1922 455277;
web: www.ramsell-naber.co.uk
Focus on energy reduction
Limited space did little to deter
one aluminium diecaster from
installing new melting facilities to
improve energy efficiences and
reduce emissions.
ZPF therm aluminium melting furnace
The Striko Westofen Group has been one of the
leading companies producing and supplying
a high efficiency range of melting plant on a
worldwide basis.
The following article was prepared by Herr Klaus Malpohl of Striko
Westofen Gmbh in 2006 to highlight several important points when
buying new melting plant. But with ever-increasing raw material costs
metal loss becomes a more important factor when installing new
equipment. For this reason it is important to reconsider the figures.
When ordering new equipment, most customers first think of
energy costs as the main consideration and then required manpower.
Striko Westofen knows that metal loss can often give greater
savings than just those associated with energy. With aluminum costs
staying high this, combined with the energy usage, can give very
significant savings.
High efficiency aluminium melting with the STRIKOMELTER
technology
With the STRIKOMELTER with patented ETAMAX technology,
the caster has an outstanding tool at his disposal, which fulfils
all requirements for the melting operation. The determination of
operational data in a foundry has confirmed the efficiency and
profitability again.
Against a background of constantly rising prices for raw materials
and energy, the question of the metal supply plays an ever larger role
for aluminium foundries in order to come up with the high market
requirements.
However, individual aspects such as gas consumption or maximum
efficient and qualitative metal yield should not be ignored in this
overall view. The metal supply is a multi dimensional system, with the
most important task consisting of supplying a casting operation with
metal of suitable quality to optimise the yield of good castings; and
of course, this must be achieved as economically as possible. In this
connection there are numerous other requirements to be taken into
consideration.
Some of these are: high melting rate with low energy consumption,
minimum metal losses and/or high metal yield and a safe and largely
automated operation. It is also necessary to consider both the current
and future environmental and safety requirements. This view should
also consider low breakdown and maintenance expenses and the
potential lining life and replacement cost.
The STRIKOMELTER fulfils all parameters by
the multi graduated use of thermal energy of
the burners as well as the innovative melting
concept. This is realised through the physical
separation into three zones: preheating, melting
and holding together with ETAMAX patented
shaft and melting design, especially developed
for the STRIKOMELTER. The choked shaft design
allows the consistent preheating of the charge
material prior to melting. The hot exhaust gases
from the holding bath pass through the melting
zone and from there into the preheating zone
and thus used several times.
The additional energy required for melting
comes from burners located in the melting zone
and focussed into the area at the base of the
preheating area; exhaust gasses from these
burners also exit through the charged material
in the shaft and therefore ensure drying and
a greater degree of preheating, and therefore
greater speed and efficiency of melting efficiency.
In that way, the charged material reaches the
melting bath in small quantities. Compared
to other furnace designs, this makes possible
substantial savings in fuel consumption and
consequent lower melting cost. In the practical
foundry operation, a power requirement by only
< 600 kWh/t was determined. This corresponds
to a thermal efficiency of over 50%.
In order to ensure good casting quality, it
is necessary to start with good metal quality.
Since aluminium is usually supplied to good
metallurgical quality standards, it is important
to ensure that no contamination is introduced
during the melting operation. This includes the
absorption of hydrogen from the atmosphere and
inclusion such as oxides and dross.
The primary source of contamination is
High efficiency Aluminium melting with the STRIKOMELTER technology
With the STRIKOMELTER with patented
ETAMAX technology, the caster has an
outstanding tool at his disposal, which ful-
fils all requirements for the melting opera-
tion. The determination of operational data
in a foundry has confirmed the efficiency
and profitability again.
Against a background of constantly rising
prices for raw materials and energy, the
question of the metal supply plays an ever
larger role for Aluminium foundries in order
to come up to the high market requirements.
However, individual aspects as gas con-
sumption or maximum efficient and qualita-
tive metal yield should not be ignored in this
overall view. The metal supply is a multi-
dimensional system, whose most important task consists of supplying a casting operation with metal of
suitable quality to optimize the yield of good castings; and of course, this must be achieved as economi-
cally as possible. In this connection there are numerous other requirements to be taken into consideration.
Some of these are high melting rate with low energy consumption, minimum metal losses and/or high metal
yield and a safe and largely automated operation. It is also necessary to consider both the current and
future environmental and safety requirements. This view should also consider low breakdown and mainte-
nance expenses and the potential lining life and replacement cost.
STRIKOMELTER
MH II-T in tilting version

The STRIKOMELTER fulfils all parameters by the multi
graduated use of thermal energy of the burners as well
as the innovative melting concept. This is realized
through the physical separation into three zones: pre-
heating, melting and holding together with ETAMAX
patented shaft and melting design, especially devel-
oped for the STRIKOMELTER. The choked shaft design
allows the consistent preheating of the charge material
prior to melting. The hot exhaust gases from the hold-
ing bath pass through the melting zone and from there
into the preheating zone and thus used several times.
The additional energy required for melting comes from
burners located in the melting zone and focussed into the area at the base of the preheating area; exhaust
gasses from these burners also exit through the charged material
in the shaft and therefore ensure drying and a greater degree of
preheating, and therefore greater speed and efficiency of melting
efficiency. In that way, the charged material reaches the melting
bath in small quantities. Compared to other furnace designs, this
makes possible substantial savings in fuel consumption and con-
sequent lower melting cost. In the practical foundry operation, a
power requirement by only < 600 kWh/t was determined. This
corresponds to a thermal efficiency of over 50 %.
STRIKOMELTER
with conveyor charging system

Process visualization
In order to ensure good casting quality, it is necessary to start with
good metal quality. Since aluminium is usually supplied to good
metallurgical quality standards, it is important to ensure that no
STRIKOMELTER

STRIKOMELTER

STRIKOMELTER

STRIKOMELTER

Cost reduction in the foundry
Melting and Holding
STRIKOMELTER with conveyor charging system
STRIKOMELTER MH II-T in tilting version Process visualisation
moisture from storage of the returns or
ingots, the result of this being an increase
in the hydrogen content of the metal with its
consequent quality problems in the cast parts.
This is avoided in the STRIKOMELTER by the
separation of melting and preheating zones.
Moisture and other contaminants are evaporated
or burnt off in the shaft by preheating with
exhaust gases, ensuring that only perfectly
dry material reaches the melting chamber. A
further advantage is the avoidance of excessive
contact of the melt with atmospheric oxygen
thereby reducing the tendency to form oxides.
In order to minimise this danger the burners in
the melt chamber are arranged to avoid direct
metal impingement. This allows melting only
on the hearth and for the metal to flow quickly
but without turbulence into the holding bath.
A third measure for the maintenance of metal
quality is the avoidance of the contamination by
impurities entering the metal holding bath. This
is assured by allowing the metal to run laterally
into the holding bath. In this way, dross and
other impurities remain on the melt hearth to be
removed during cleaning.
An additional advantage of the separation
of the two chamber concept is a continuous
availability of molten metal at a very consistent
temperature (to +/- 5C). This type of melting
system guarantees continuous melting whilst
tapping liquid metal. The automated charging
contributes to achieving a molten metal
availability of 98% during practical operation.
Measured data in foundry practice
The data stated by the manufacturer were
confirmed in the industrial high pressure die-
casting foundry of W Hesse & Bauckhage GmbH
in Germany in the autumn of 2005. Since 2001
there have been two STRIKOMELTER systems in
use in this foundry; these are MH II-N 2000/1000
G-eg units and the investigation was based on
the following operating conditions:
Alloy: 231 D, AlSi12Cu1 (Fe) EN-AC
47100
- StrikoWestofen GmbH
239, EN-AC-43000
- customer -
Employment: 50% ingots 5-7 kg
50% dry returns, size - 0.3-2 kg
with some flitter
Other: Flux was used on the melting
ramp and in the holding bath
The investigation examined both the gross and the net metal
yields. Using only ingot, a gross yield (ratio of initial metal weight to
the metal weight at the tap) was determined at 99.75%.
Using a charge of 50% ingots and 50% returns the value was
approx. 99.40%. The net yield refers to the metal after additional
drossing operations in the ladle; for this, the weight of the 300-kg-
ladle before and after drossing was measured on a precision weight
scale. Table 1 contains the results of the net metal yields achieved in
the foundry as well as previous reference values. They show that the
metal losses were in all cases below 1%.
The manufacturer data for metal loss specified in brochures were
therefore not only confirmed, but clearly exceeded.

Financial and technical advantages
Based on the determined values, the enormous advantages of the this
particular system can be calculated as follows:
Metal price 2,400 /t
Total melting times 6,600 h/a
Melting capacity 1 t/h
Increased metal yield by 1%
Savings / pa 158,000
The increased metal yield by only 1% permits a yearly saving of
158,000! In comparison to many older furnace units with metal
losses of up to 8%, enormous saving potentials occur in connection
to the clearly higher efficiency of the sysytem. The investment in the
modern STRIKOMELTER technology enables extremely short pay
back periods of 6 to 12 months.
A further financial factor is the savings in energy due to the high
efficiency of the ETAMAX technology as well as a substantially low
scrap rate due to the better molten metal quality.
StrikoWestofen GmbH, Wiehl, Germany, July 2006
contamination is introduced during the melting operation. These include the absorption of hydrogen from the
atmosphere and inclusion such as oxides and dross.
The primary source of contamination is moisture from storage of the returns or ingots, the result of this
being an increase in the hydrogen content of the metal with its consequent quality problems in the cast
parts. This is avoided in the STRIKOMELTER by the separation of melting and preheating zones. Moisture
and other contaminants are evaporated or burnt off in the shaft by preheating with exhaust gases, ensur-
ing that only perfectly dry material reaches the melting chamber. A further advantage is the avoidance of
excessive contact of the melt with atmospheric oxygen thereby reducing the tendency to form oxides. In
order to minimize this danger the burners in the melt chamber are arranged to avoid direct metal im-
pingement. This allows melting only on the hearth and for the metal to flow quickly but without turbulence
into the holding bath. A third measure for the maintenance of metal quality is the avoidance of the con-
tamination by impurities entering the metal holding bath. This is assured by allowing the metal to run later-
ally into the holding bath. In this way, dross and other impurities remain on the melt hearth to be removed
during cleaning.
An additional advantage of the separation of the 2 chamber concept is a continuous availability of molten
metal at a very consistent temperature (to +/- 5C). This type of STRIKOMELTER guarantees continuous
melting whilst tapping liquid metal. The automated charging contributes to achieving a molten metal avail-
ability of 98% during practical operation.
The data stated by the manufacturer were confirmed in the industrial high pressure die-casting foundry of
W. Hesse & Bauckhage GmbH in Germany in the autumn of 2005. Since 2001 there have been two
STRIKOMELTER in use in this foundry; these are MH II-N 2000/1000 G-eg units and the investigation was
based on the following operating conditions:
STRIKOMELTER at Hesse & Bauckhage
Alloy: 231 D, AlSi12Cu1 (Fe) EN-AC 47100
239, EN-AC-43000
- customer -
50% dry returns, size - 0.3-2 kg with some flitter
Other: Flux was used on the melting ramp and in the
holding bath
salt
salt
exhaust gas
initial
metal
weight
[ kg ]
return
material,
+
bulky
material
to DCM;
output metal
weight (net)
dross in
the shaft
dross on
the bath
output
metal
weight
(gross)
dross in the ladle
with / without melt
treatment
dross take-off from furnace
melt
treatment
in the ladle:
- adding of salts
- impeller,
salt
metal
portion
salts +
metal oxides
The investigation examined both the gross and
the net metal yields. Using only ingot, a gross
yield (ratio of initial metal weight to the metal
weight at the tap) was determined at 99, 75%.
Using a charge of 50% ingots and 50% returns
the value was approx. 99, 40%. The net yield
refers to the metal after additional drossing op-
erations in the ladle; for this, the weight of the
300-kg-ladle before and after drossing was
measured on a precision weight scale. Table 1
contains the results of the net metal yields
achieved in the foundry as well as previous re-
ference values. They show that the metal
losses were in all cases below 1%.

Draft testing procedure
contamination is introduced during the melting operation. These include the absorption of hydrogen from the
atmosphere and inclusion such as oxides and dross.
The primary source of contamination is moisture from storage of the returns or ingots, the result of this
being an increase in the hydrogen content of the metal with its consequent quality problems in the cast
parts. This is avoided in the STRIKOMELTER by the separation of melting and preheating zones. Moisture
and other contaminants are evaporated or burnt off in the shaft by preheating with exhaust gases, ensur-
ing that only perfectly dry material reaches the melting chamber. A further advantage is the avoidance of
excessive contact of the melt with atmospheric oxygen thereby reducing the tendency to form oxides. In
order to minimize this danger the burners in the melt chamber are arranged to avoid direct metal im-
pingement. This allows melting only on the hearth and for the metal to flow quickly but without turbulence
into the holding bath. A third measure for the maintenance of metal quality is the avoidance of the con-
tamination by impurities entering the metal holding bath. This is assured by allowing the metal to run later-
ally into the holding bath. In this way, dross and other impurities remain on the melt hearth to be removed
during cleaning.
An additional advantage of the separation of the 2 chamber concept is a continuous availability of molten
metal at a very consistent temperature (to +/- 5C). This type of STRIKOMELTER guarantees continuous
melting whilst tapping liquid metal. The automated charging contributes to achieving a molten metal avail-
ability of 98% during practical operation.
The data stated by the manufacturer were confirmed in the industrial high pressure die-casting foundry of
W. Hesse & Bauckhage GmbH in Germany in the autumn of 2005. Since 2001 there have been two
STRIKOMELTER in use in this foundry; these are MH II-N 2000/1000 G-eg units and the investigation was
based on the following operating conditions:
Alloy: 231 D, AlSi12Cu1 (Fe) EN-AC 47100
239, EN-AC-43000
- customer -
50% dry returns, size - 0.3-2 kg with some flitter
Other: Flux was used on the melting ramp and in the
holding bath
salt salt
exhaust gas
initial
metal
weight
[ kg ]
return
material,
+
bulky
material
to DCM;
output metal
weight (net)
dross in
the shaft
dross on
the bath
output
metal
weight
(gross)
dross in the ladle
with / without melt
treatment
dross take-off from furnace
melt
treatment
in the ladle:
- adding of salts
- impeller,
salt
metal
portion
salts +
metal oxides
The investigation examined both the gross and
the net metal yields. Using only ingot, a gross
yield (ratio of initial metal weight to the metal
weight at the tap) was determined at 99, 75%.
Using a charge of 50% ingots and 50% returns
the value was approx. 99, 40%. The net yield
refers to the metal after additional drossing op-
erations in the ladle; for this, the weight of the
300-kg-ladle before and after drossing was
measured on a precision weight scale. Table 1
contains the results of the net metal yields
achieved in the foundry as well as previous re-
ference values. They show that the metal
losses were in all cases below 1%.

Draft testing procedure
Melting and Holding
Draft testing procedures
Measured values at Hesse & Bauckhage
The manufacturer data for
metal loss specified in
brochures were therefore
not only confirmed, but
clearly exceeded.
Financial and technical advantages
Based on the determined values, the enormous advantages of the STRIKOMELTER can be calculated as
follows:
Metal price 2.400 /t
Total melting times 6.600 h/a
Melting capacity 1 t/h
Increased metal yield by 1%
Savings / pa 158.000
The increased metal yield by only 1 % permits a yearly saving of 158.000 ! In comparison to many older
furnace units with metal losses of up to 8 %, enormous saving potentials occur in connection to the clearly
higher efficiency of the STRIKOMELTER. The investment in the modern STRIKOMELTER technology en-
ables extremely short pay back periods of 6 to 12 months.
A further financial factor is the savings in energy due to the high efficiency of the ETAMAX technology as
well as a substantially low scrap rate du to the better molten metal quality.
StrikoWestofen GmbH, Wiehl, Germany, July 2006
StrikoWestofen GmbH
Fritz Kotz Str. 2-4
D 51674 Wiehl
Tel + 49 / 2261 / 70 91 0
Fax + 49 / 2261 / 70 91 107
sales@strikowestofen.com
www.strikowestofen.com
Charged material 100 % ingots 50 % ingots
50 % returns
StrikoWestofen values
EN AC-47100 / 231 D
Metal yield %
99.55 % 99.20 %
HeBa values
EN AC-43000 / 239
Metal yield %
99.61 % 99.01 %
Measured values at Hesse & Bauckhage
Background
Fuel prices have been rising at such a rapid rate
in recent months that foundries everywhere are
finding it increasingly difficult to remain cost
effective and competitive, so they are looking to
significantly reduce their energy consumption.
Morgan Molten Metal Systems is a global
manufacturer and supplier of foundry crucibles,
furnaces and associated metal handling and
treatment products. With over 150 years in
the foundry business, Morgan has developed a
leading position and enviable reputation for its
truly integrated crucible based metal melting and
holding systems. The company says its success
stems from the fact it designs and manufactures
both the crucibles and the furnaces. Morgan
understands that optimising the performance
of any metal melting and holding process in the
foundry is dependent on balancing a complex
set of variables; the furnace, customer working
practices, crucible and metallurgical processes all
interact. So to achieve the balance required, the
system needs application specific design for both
the consumables and the equipment.
From this technological background, Morgan
MMS was keen to address the concerns that
foundries had expressed about their rising fuel
bills so they set out to design a molten metal
system that used fuel in a much more efficient way,
such that it could significantly
reduce foundries fuel costs. To
achieve this they looked to their
own existing technology and
how it could be redesigned and
enhanced.
Recuperation on furnaces is
not a new concept, having been
around since the early 1900s.
Take up of the technology
accelerated during the 1970s
oil crisis, which created similar
problems to those being
experienced today - rising
energy costs and supply
restrictions. Morgan was quick
at the time to respond to
the situation and developed
a range of crucible furnaces
incorporating a recuperation
technique which would utilise
fuel more efficiently. To address
the latest fuel crisis they took
another look at recuperation
and set out to improve the
efficiency and cost effectiveness
of the technology to breathe
new life into the recuperator
system.
So what is recuperation?
A recuperator recycles waste
heat from the exhaust gases to
pre-heat the combustion air to
the burner. It achieves this via
a counter-flow heat exchanger
which, on a crucible furnace,
replaces the standard exhaust
stack. The recuperator transfers
waste heat in the exhaust to the
Save Money with Morgan Recuperative Crucible Furnaces

Dr Andy Wynn, Global Technical Director, andy.wynn@morganplc.com
Bob Thomas, Chief Furnace Engineer, bob.thomas@morganitecrucible.com
Tim Heeks, Furnace Design Engineer, tim.heeks@morganitecrucible.com
Morgan Molten Metals Systems
Woodbury Lane
Norton
Worcester
WR5 2PU

INTRODUCTION

Does this sound familiar?

My energy costs are rising out of control!

Our energy bill this year is double what it was last year!

We hear these comments every day of the week when visiting non-ferrous foundries
all over the world.

Want to know how to reduce your energy bill and save money? Well dont worry,
new technology is now available to solve this problem for you. Morgans new
recuperative crucible furnace range is the answer youre looking for.

Morgan Recuperative
Gas Fired Crucible Furnace
Want to know how to reduce your energy
bill and save money? New technology is
now available to solve this growing problem
and Morgan Molten Metal Systems say its
new recuperative crucible furnace range is
the answer.
Reduce your energy bill with new technology
Melting and Holding
BACKGROUND

Fuel prices have been rising at such a rapid rate in recent months that foundries
everywhere are finding it increasingly difficult to remain cost effective & competitive.
So foundries are looking to significantly reduce their energy consumption in order to
remain competitive.

Morgan Molten Metal Systems is a global manufacturer and supplier of foundry
crucibles, furnaces and associated metal handling and treatment products. With over
150 years in the foundry business, Morgan has developed a leading position and
enviable reputation in the market worldwide, as it can offer truly integrated crucible
based metal melting & holding systems. This is because it designs and manufactures
both the crucibles and the furnaces. Morgan understands that optimising the
performance of any metal melting and holding process in the foundry is dependent on
balancing a complex set of variables. The furnace, customer working practices,
crucible and metallurgical processes all interact. So to achieve the balance required,
the system needs application specific design for both the consumables and the
equipment.

From this technological background, Morgan MMS was keen to address the concerns
that foundries had expressed about their rising fuel bills. We set out to design a
molten metal system that used fuel in a much more efficient way, such that it could
significantly reduce foundries fuel costs. To achieve this we looked to our existing
technology and how we might redesign and enhance it.

Recuperation on furnaces is not a new concept, having been around since the early
1900s. Take up of the technology accelerated during the 1970s oil crisis, which
created similar problems with rising energy costs and supply restrictions as we are
experiencing today. Morgan was quick at the time to respond to the situation and
developed a range of crucible furnaces incorporating a recuperation technique which
would utilise fuel more efficiently. To address our latest fuel crisis we took another
look at recuperation and set out to improve the efficiency and cost effectiveness of the
technology to breathe new life into the recuperator system.

Metallurgy
Working
Practice
Furnace

EXCEL E
SO WHAT IS RECUPERATION?

A recuperator recycles waste heat from the exhaust gases to pre-heat the
combustion air to the burner. It achieves this via a counter-flow heat exchanger which
on a crucible furnace replaces the standard exhaust stack. The recuperator transfers
waste heat in the exhaust to the combustion air entering the fuel burner, thus
preheating it. Since the gases have been pre-heated, less fuel is needed to heat those
gases to the required furnace melting/holding temperatures.

The recuperator technique is used for heat recovery in many other industries, such as
chemical plants and refineries, in applications where there is fluid-fluid counter flow
and in closed system processes such as in refrigeration cycles. There are several other
systems of heat recovery available including the regenerative heat exchanger, the
rotating recuperator and energy recovery ventilation, but the standard recuperator is
the system that works best with fuel burner applications, to increase the overall
efficiency, and for this reason is used in gas turbine engines.

By recovering some of the energy usually lost as waste heat, the recuperator makes a
fuel fired crucible furnace significantly more efficient. Morgans unique position as a
designer of both furnaces and crucibles allowed us to significantly enhance the
efficiency of the design of the recuperative system as applied to fuel fired crucible
furnaces, through optimal selection of materials and components and true integration
of design. Instead of just bolting a recuperator system onto an existing furnace, we
understood that optimum efficiency would only come by starting from first principles,
and so we set out to create a design which truly integrated the recuperator with the
furnace and the crucible. The result of this development work is the new range of
Morgan Recuperative Furnaces, available as both static bale out and as tilting systems
to provide foundries with the lowest gas bills possible at both the casting and melting
stations.

Air and Gas Components
combustion air entering the fuel
burner, thus preheating it. Since
the gases have been pre-heated,
less fuel is needed to heat those
gases to the required furnace
melting/holding temperatures.
The recuperator technique
is used for heat recovery in
many other industries, such as
chemical plants and refineries,
in applications where there is
fluid-fluid counter flow and
in closed system processes
such as in refrigeration cycles.
There are several other systems
of heat recovery available
including the regenerative
heat exchanger, the rotating
recuperator and energy recovery
ventilation, but the standard
recuperator is the system that
works best with fuel burner
applications, to increase the
overall efficiency. For this
reason it is used in gas turbine
engines.
By recovering some of the
energy usually lost as waste
heat, the recuperator makes
a fuel fired crucible furnace
significantly more efficient.
Morgans unique position as
a designer of both furnaces
and crucibles allowed them
to significantly enhance the
efficiency of the design of the
recuperative system as applied
to fuel fired crucible furnaces,
through optimal selection of
materials and components
and true integration of design.
Instead of just bolting a
recuperator system on to
an existing furnace, they
understood that optimum
efficiency would only come by
starting from first principles,
and so they set out to create a
design which truly integrated
the recuperator with the furnace
and the crucible. The result
of this development work
is the new range of Morgan
recuperative furnaces, available
as both static bale out and
as tilting systems to provide
foundries with the lowest gas
bills possible at both the casting
and melting stations.
Performance benefits
Due to the integrated design,
the range of recuperative
furnaces gives a number of
benefits to the foundry far
beyond the key advantage of
lowering their gas bill and they
are considered here.
Cost effective
The company says the new
technology incorporated into
the recuperative system makes
it the most cost effective
product of its kind. Existing
recuperative products on the
market quote a maximum of
25% energy reduction compared
with an equivalent non-
recuperative furnace. Morgans
new recuperative technology
provides a minimum of 35%
energy reduction, and often
higher. At some foundries,
as high as 50% reduction in
gas usage can be achieved,
compared to their existing
firebrick lined gas-fired
furnaces.
The cost savings achieved by
more efficient use of gas from
the new recuperator technology
are enhanced by incorporating
the very latest refractory and
insulation technology into the
furnace design. Using the latest
materials technology developed
within the Morgan Crucible
Group provides the lowest level
of thermal conductivity available
commercially, which minimises
heat losses from the furnace
chamber. Melting efficiencies
as high as 40% are achieved,
compared to conventional gas-
fired crucible furnaces, where
20-25% is typical.
The new recuperative furnace
also delivers more cost effective
running costs in terms of longer
consumable life. Crucible life
is enhanced due to the fully
modulating burner technology,
which has two advantages in
terms of crucible life. Firstly it
burns very close to stoichiometric combustion, so
that no excess oxygen is present in the furnace
chamber, which would otherwise attack the high
graphite and carbon content of the crucible causing
oxidation. Secondly it introduces a high velocity
gas stream into the chamber, which creates an even
heat distribution over the whole crucible, ensuring
no hot spots exist that would otherwise cause
thermal stresses, leading to distortion. This highly
efficient thermal design feature is further enhanced
by the hot face chamber lining, which incorporates
Morgans patented gas radiant panel technology
which radiates heat directly on to the crucible and
thereby to the metal, rather than traditional brick
designs, which allow more heat to be lost to the
stack as waste.
The new integrated recuperative furnace
design also facilitates fast commissioning times,
minimising foundry downtime, if replacing a non-
recuperative unit. Traditional recuperative designs
are constructed using separate floor mounted
components, with gas pipes trailing across the
foundry floor. This leads to long and complicated
installation and commissioning times and presents
health and safety risks to the operator and risk of
damage to the critical components from fork-lift
traffic in the foundry.
Optimum metal quality
The same technological features that minimise the
running costs of the new recuperative furnace also
contribute to delivering optimum metal quality. The
fully modulating, high turn down ratio burner gives
tight control of metal temperature typically down
to 5C, allowing foundries to achieve the stringent
quality controls required for modern automotive
castings, reducing rejects and minimising costly
metal losses. The gas flow design is such that the
exhaust gases exit from the side of the chamber,
not over the top of the crucible, ensuring that
gases do not contact the molten metal, thus
minimising the potential for gas pick up which
would otherwise lead to porosity in castings.
Health, safety and the Environment
With operator comfort and safety in mind the highly
efficient insulation which helps minimise running
costs also ensures that casing temperatures are low
and that the ambient temperature of the working
Melting and Holding
PERFORMANCE BENEFITS

Due to the integrated design, the Morgan range of recuperative furnaces hosts a range
of benefits to the foundry far beyond the key advantage of lowering their gas bill;

COST EFFECTIVE

The new technology incorporated into the recuperative system makes it the most cost
effective product of its kind. Existing recuperative products on the market quote a
maximum of 25% energy reduction compared with an equivalent non-recuperative
furnace. Morgans new recuperative technology provides a minimum of 35% energy
reduction, and often higher. At some foundries, as high as 50% reduction in gas usage
can be achieved, compared to their existing firebrick lined gas-fired furnaces.

The cost savings achieved by more efficient use of gas from the new recuperator
technology are enhanced by incorporating the very latest refractory and insulation
technology into the furnace design. Using the latest materials technology developed
within the Morgan Crucible Group provides the lowest level of thermal conductivity
available commercially, which minimises heat losses from the furnace chamber.
Melting efficiencies as high as 40% are achieved, compared to conventional gas-fired
crucible furnaces, where 20-25% is typical.

The new recuperative furnace also delivers more cost effective running costs in terms
of longer consumable life. Crucible life is enhanced due to the fully modulating
burner technology, which has two advantages in terms of crucible life. Firstly it burns
very close to stoichiometric combustion, so that no excess oxygen is present in the
furnace chamber, which would otherwise attack the high graphite and carbon content
of the crucible causing oxidation. Secondly it introduces a high velocity gas stream
into the chamber, which creates an even heat distribution over the whole crucible,
ensuring no hot spots exist that would otherwise cause thermal stresses, leading to
distortion. This highly efficient thermal design feature is further enhanced by the hot
face chamber lining, which incorporates Morgans patented gas radiant panel
technology which radiates heat directly onto the crucible and thereby to the metal,
rather than traditional brick designs, which allow more heat to be lost to the stack as
waste .

Integrated Design

Gas Radiant Panel
environment is as comfortable as possible. The
unique burner design also reduces noise levels
during use of the furnace to unparalleled levels,
with under 75dBA measured at 2m from the unit,
which is below current regulations for the UK
requiring PPE action.
The new burner technology in Morgans
recuperative crucible furnace also has the
added benefit of reducing greenhouse gaseous
emissions. Typical CO
2
emissions for a BT1300
size furnace are reduced to ~12 tonnes per year
compared to ~20 tonnes per year for a non-
recuperative equivalent furnace run under the
same conditions. Raising the temperature of the
input air by recuperation also raises the level of
NO
x
generated, such that conventional recuperative
forced air burners run above 400ppm. Input air is
typically pre-heated up to 250C in a recuperative
crucible furnace. Under these conditions Morgans
recuperative burner technology reduces NO
x

emissions below 125ppm.
Foundries save money
Initial foundry trials of the new recuperative
technology started in the UK, where the technology
was developed. Following initial commercialisation
in Europe, Morgans newest furnace technology is
now being utilised successfully in other markets.
In work with foundries across the world, typically,
a project to optimise their melting and holding
foundry to find that the investment in new recuperative furnaces is paid for within two
years just by the reduction on their gas bill. On top of this, there is often additional
financial support available in terms of government grants and loans available to
support energy saving and carbon footprint reduction schemes. In the UK the Carbon
Trust provides interest free loans to fund the purchase of energy efficient capital
equipment to reduce carbon emissions. Similar schemes are available in a number of
other countries.

practices will start with a
detailed audit of the foundrys
existing capabilities and a
comparison with their energy
costs, working practices and
alloy demands. To complement
the recuperative technology
Morgan has developed a series
of analytical tools which can
help a foundry identify where
it can save money on gas bills.
Invariably, the biggest potential
saving identified is replacement
of the existing furnaces with
this new recuperative furnace
technology. Depending on the
state of the furnaces being
replaced and the gas price, it is
not uncommon for a foundry to
find that the investment in new
recuperative furnaces is paid
for within two years just by the
reduction on the gas bill. On top
of this, there is often additional
financial support available in
terms of government grants and
loans to support energy saving
and carbon footprint reduction
schemes. In the UK the Carbon
Trust provides interest free
loans to fund the purchase
of energy efficient capital
equipment to reduce carbon
emissions. Similar schemes are
available in a number of other
countries.
For more information contact:
Dr Andy Wynn, global technical
director, e: andy.wynn@
morganplc.com or Bob Thomas,
chief furnace engineer, e: bob.
thomas@morganitecrucible.
com or Tim Heeks, furnace
design engineer, e: tim.heeks@
morganitecrucible.com at Morgan
Molten Metals Systems, Woodbury
Lane, Norton, Worcester WR5 2PU.
UK.
Web: www.morganmms.com
Melting and Holding
Introducing...
...the latest in improved technology
for your foundry,
MORGAN MOLTEN METAL SYSTEMS
Recuperative Furnace:
CRUCIBLE LTD
MORGANITE
MORGANITE CRUCIBLE LTD
Woodbury Lane
Norton, Worcester WR5 2PU
Tel: +44 (0) 1905 728200
Fax: +44 (0) 1905 767877
Web: www.morganmms.com
Realize these benefits with this
new furnace:
Up to 50% energy savings
Improved crucible life
Very low noise emissions
Environmentally
friendly emissions
Having an all steel construction up to 1,000kg
capacity, the new compact furnace bodies can
easily be connected to all brands of inverter
system and in most cases without the need for any
modification to existing brickwork.
Up to 1,000kg steel capacity, the industry
has historically favoured unscreened box type
tilting bodies, this trend has been largely down
to economic and maintenance considerations. As
a knock-on effect, todays second-hand furnace
market limits customers choice as to the brand
and style of equipment available. In Meltechs
experience the market for furnace bodies outstrips
whole-system sales by around two to one and in
some cases has hampered sale potential because
quite simply, there were not enough loose bodies
available at the time to meet demand.
Limitations in availability and changing market
trends were the catalyst which encouraged
engineers at the UK based supplier to study the
possibility of developing a furnace body. In order
to succeed, the new system would have to meet
an exacting specification to include features which
were common to much larger steel frame or shell
furnaces but with simplicity and build cost equal
to, or better than, a box furnace.
Study complete . . furnace designed
Today, some 12 months after that initial study was
completed, the new furnace has been designed,
built, tested and certified with the first two units
now sold and completing commissioning trials.
The Mag-Melt furnace body has a fabricated
steel construction, which is magnetically screened,
utilising air cooled shunt gap technology offering
improved efficiency compared to other steel shell
or steel frame furnaces. Power ratings of well
above 750kw on a 1,000kg body are achievable.
On the 500kg capacity units already constructed,
fussy water manifold arrangements and shunt
cooling circuits common to other steel furnaces
have been completely designed out, leaving the
interior of the body uncluttered
and free of pipe work. Each
shunt is easily lifted out by
undoing just two retaining
bolts. Unlike most other
furnaces, there are no shunt
compression bolts present on
the furnace either, inside or out.
In addition to the
simplification of the water
circuitry, there has been further
development. This includes
the almost total removal
of combustible insulation
materials within the furnace,
anywhere other than on the coil
itself, thus reducing ground
fault problems associated with
charred or burnt insulators.
This is possible by the clever
use of refractory within the
body which has eliminated the
need for coil backing materials,
Mica, insulation tubes, top hat
washers and so on.
While it is not possible to
eliminate lining failure, metal
run through and damage to any
furnace, the Mag-Melt design
does reduce potential electrical
or ground fault problems.
However, should they occur,
the simplicity of the furnace
construction also allows the
damaged coil to be removed in
minutes by undoing just four
bolts and the power leads.
Certification conformity
The furnaces meet all current
and proposed EMF regulations
and come with a certificate
of conformity. Options
include hydraulic lid, lip fume
extraction, refractory push out
and pre-tilt system for accurate
pour control.
Steve Macey of Meltech
explains the importance and the
customer reaction to this new
product line. We accepted our
first two orders for Mag-Melt
furnace bodies several weeks
ago. Customers seem impressed
with the thought we have put
into the product. For example,
our access cover has proper
lifting handles, big enough to
take hands wearing heavy-duty
gloves a small but important
point that demonstrates our
complete attention to detail.
Our design people have years
of experience fixing all makes
of systems and understand the
advantages and disadvantages.
They have been innovative and
used a systematic approach to
manufacture, and for that they
must take the credit for this
product.
Meltech is also the service
and sales agent for ABP
induction and supply their
induction melting and heating
equipment to the UK and
Ireland.
Meltech Ltd.
Tel: +44 (0) 1902 722588;
fax: +44 (0) 1902 730142;
email: steve@induction-furnaces.
co.uk
web: www.induction-furnaces.co.uk
New induction furnace body hits the market
Meltech Ltd has introduced a new
range of compact furnace bodies
designed specifically for the small and
medium foundry.
Mag-Melt furnaces meet all current and proposed EMF regulations and
come with a certicate of conformity

Melting and Holding October 08

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252 FTJ October 2008

Primary materials have become limited on the

MH II-T in tilting version

with conveyor charging system

MH II-T in tilting version

with conveyor charging system

MH II-T in tilting version

with conveyor charging system

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